Biodata: Mr. Alan Leong Position/Company: Senior Researcher, PETRONAS ...portal.malaysiangas.com/document/publication/1318613510_1430_Alan… · Biodata: Mr. Alan Leong Position/Company:

Biodata of Speaker :-

Biodata: Mr. Alan Leong

Position/Company: Senior Researcher, PETRONAS Research Sdn. Bhd. (PRSB)

Mr. Alan Leong graduated with Bachelors degree in Aerospace engineering but been

working with composite materials since 2000. He specialises in composites testing and low

cost composites manufacturing techniques, and worked in University of London on

composite materials for wind turbines prior to joining PETRONAS. Alan joined PETRONAS

Research Sdn Bhd in 2007 and has been working on the application of composites materials

in O&G, specifically in the field of repair and rehabilitation.

Abstract of Papers:-

Title: ““PIPEASSURETM Composite Repair and Rehabilitation of Risers and Pipelines”

This paper describes the work carried out to develop, test and field-demonstrate the

Pipeassure™ composite overwrap system capable for use in the repair and/or corrosion

protection of pipeline and risers in the oil and gas industry. The system is applicable in dry

conditions, e.g. for pipelines and sections of risers at and close to the platform; in wet

conditions, e.g. risers at the splash zones; and in fully submerged underwater conditions,

e.g. for subsea pipelines. Pipeassure™ is currently being qualified to ISO 24817 and results

from the testing program and field demonstrations will be presented.

By

KH Leong, AYL Leong, YC Tan, PFM Liew (PETRONAS)

CD Wood, W Tian & KA Kozielski (CSIRO)

© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS)All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.

Presented at the

7th Asian Pipeline Conference and Exhibition

Kuala Lumpur, Malaysia

11 – 12 October 2011

PIPEASSURE™ COMPOSITE REPAIR

AND REHABILITATIION OF RISERS

AND PIPELINES

© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011

Benefits of Composite Repairs

Patch and Overwrap Repairs

PipeAssure™

Experimental: Materials development

Resin development

Prepregging

Characterisation and Testing

Results and Discussion

Field Demonstrations

Summary and Conclusions

Outline

1


• Why composites repair?– operational efficiency

– occupational safety

– flexibility

• Advantageous properties– corrosion resistance

– superior mechanical performance

– lightweight

– good thermal insulation

– design flexibility

– cost-effective

Benefits of Composite Repairs

5

Source: http://en.wikipedia.org



Source: CRC-ACS

http://en.wikipedia.org/wiki/File:Cfaser_haarrp.jpg

http://en.wikipedia.org/wiki/File:Kohlenstofffasermatte.jpg


Overwrap repairs have been used to repair, rehabilitate and

rejuvenate piping, risers and also pressure vessels.

Patch and Overwrap Repairs

Source: Malcolm, Reinf. Plast., 2009. Source: Beckman, Offshore, 2005.

References: 1. Furlow, Offshore,

2002.

The patch is adhesively bonded to the substrate to repair the damage

http://www.reinforcedplastics.com/_virtual/article-images/Figure-1-49600.JPG


• PIPEASSURE™ is a novel pre-impregnated composite resin system for pipeline repairs, both onshore and offshore.

• Consists of “E-Glass fibre” pre-impregnated with a proprietary underwater epoxy resin formulation with effective corrosion protection and pipe reinforcement properties.

• PIPEASSURE™ is curable underwater and is capable of withstanding wet environments with minimal loss of adhesion and mechanical properties.

PIPEASSURE™

7

+ =


Experimental

4

Chemical approach to tailor propertiesMatrix resin

A blend of liquid & solid epoxy Nanoclay for reinforcement Surfactants Silane cure promoter

Hardener Amine hardener

Pre-impregnationMaterials

CSM backed E-glass plain woven fabric

Characterisation and mechanical testingGlass transition temperature (Tg) vs cure

time/temperature @ 30, 40, 90°CSalt spray @ 4500 hrsTransverse adhesion (“Dolly”)Hardness (Shore D)

Qualification Testing Program

Based on ISO/TS 24817 PETRONAS Technical Standard

for Coatings

Coupon Pipe spool

hole, and wall thinning

Two conditions Dry Wet

Field Demonstrations


Established necessary process controls 750 gsm CSM based plain weave glass fabric

> 50wt% resin content

30cm wide tape

460g per lineal metre

15 - 20m rolls

Largest batch produced

to-date 750m (in a day)

Results: Prepreg Production

6


Characterisation and Testing

10

Mechanical Properties Testing

Lap Shear

Thermal properties – Tg

CTE & Fire

Long Term ConditioningCathodic Disbondment

Adhesion

Accelerated Weathering

Hydrostatic Pressure Test


Results: Resin Characterisation

5

Cure duration

Estimate cure duration based on cure temperature

-20

0

20

40

60

80

100

120

0 2 4 6 8 10 12 14 16

Gla

ss t

ran

siti

on

tem

per

atu

re, T

g (o

C)

Cure duration (days)

Resin glass transition temperature (Tg) for different cure conditions

30°C 40°C 90°C

0

20

40

60

80

100

-20 0 20 40 60 80 100 120

Deg

ree

of

cure

(%

)

Glass transition temperature, Tg (oC)

Degree of cure versus Tg

Cured glass transition temperature

In-situ estimation of level of cure


Results: System Characterisation

7

0 hr 2000 hrs


Results: Qualification Program (In progress)

8

Out of Water In WaterTested @ RT Tested @ 55°C Tested @ RT Tested @ 55°C

Long. Modulus (GPa) 17.5 16.7 16.7 16.7

Trans. Modulus (GPa) 16.4 15.3 15.3 16.8

Long. Strength (MPa) 233 229 226 205Trans. Strength (MPa) 214 214 189 168Poisson’s Ratio 0.19 0.19 0.19 0.18

Lap Shear (MPa) 14.37a 14.83Tests to be carried out

Tests to be carried out

Transverse Adhesion (MPa) 18.5a - 8.6b -Tg (°C) 76 - 100 -Short term pipe spool survival test

Passedto 326bar c

-Tests to be carried out

-

a With PR25 out-of-water primer.

b With PR30 in-water primer.

c Repair was holding pressure at 380bar when steel pipe yielded.

NB Energy release rate: 96 J/m2


Field Demonstrations: Corrosion Protection

9

Surface Prep Installing Repair Quality Control Post-installation Monitoring

Topside Splash zone

Topside

Splash zone

Hardness measurement

Adhesion measurement

Grit blasting to achieve

SA2.5 surface finish

Carried out on 3 risers

Month 2, 7, 9, 12


Field Demonstrations: Leak Repair

9

Surface Prep Installing Repair Quality Control Post-installation Monitoring

Hardness measurement

Carried out on vessel

Month 3 & 6

Live repair ~95oC


Summary and Conclusions

11

A newly developed resin composite overwrap system has been successfully demonstrated for offshore riser repair/maintenance.

Substantial amount of testing, especially with regard to the performance of the material as a repair/ coating system for both dry and wet conditions, has been carried out prior to the field trials.

Post-installation inspections on the risers carried out after 2, 7, 9 and 12 months have revealed no discernible sign of any damage or degradation of key properties in the composite overwrap. This was confirmed through destructive tests that were carried out on the “dummy” test plate set adjacent to the riser repairs.

The developmental testing is currently undergoing verification through a comprehensive third-party qualification program per ISO/TS 24817 for the system to be used in structural repairs.


Thank You …..

www.petronas.com.my

For further information, please contact:

KH Leong

PETRONAS Research Sdn BhdT & E DivisionPETRONAS

Lot 3288 – 3289 Off Jalan Ayer ItamKawasan Institusi Bangi43000 KajangSelangor DEMALAYSIA

T +603 8928 1588M +6012 305 6272e [email protected] w www.petronas.com.my

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